Miller FieldPro Feeder CE, FieldPro Feeder Non-CE Owner's Manual

OM-267043F 2016−07

Processes

MIG (GMAW) Welding
Flux Cored (FCAW) Welding

Description

Wire Feeder

™

FieldPro Feeder

(With Weld Cable Control)

CE And Non−CE Models

Visit our website at

www.MillerWelds.com

File: MIG (GMAW)

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.

That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.

Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The

Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.

parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.

Working as hard as you do

− every power source from
Miller is backed by the most
hassle-free warranty in the
business.

Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 2009−09

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1.................................

1-1. Symbol Usage 1.......................................................................

1-2. Arc Welding Hazards 1.................................................................

1-3. Additional Symbols For Installation, Operation, And Maintenance 3.............................

1-4. California Proposition 65 Warnings 4......................................................

1-5. Principal Safety Standards 4.............................................................

1-6. EMF Information 4.....................................................................

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5...........................

2-1. Symboles utilisés 5.....................................................................

2-2. Dangers relatifs au soudage à l’arc 5......................................................

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7.....

2-4. Proposition californienne 65 Avertissements 8..............................................

2-5. Principales normes de sécurité 8.........................................................

2-6. Informations relatives aux CEM 8.........................................................

SECTION 3 − DEFINITIONS 9..................................................................

3-1. Additional Safety Symbols And Definitions 9................................................

3-2. Miscellaneous Symbols And Definitions 10..................................................

SECTION 4 − SPECIFICATIONS 11..............................................................

4-1. Serial Number And Rating Label Location 11................................................

4-2. Unit Specifications 11....................................................................

4-3. Environmental Specifications 11...........................................................

4-4. Wire Type, Size, and Feed Speed Capability Table 12.........................................

4-5. Gun Recommendation Table 12...........................................................

SECTION 5 − INSTALLATION 13................................................................

5-1. Equipment Connection Diagram 13........................................................

5-2. WCC (Weld Cable Control) Applications 13..................................................

5-3. Associating Wire Feeder To PipeWorx 350 FieldProt 13......................................

5-4. Equipment Setup 14.....................................................................

5-5. Installing Drive Rolls 15..................................................................

5-6. Connecting Welding Gun And Voltage Sensing Clamp 16......................................

5-7. Connecting Shielding Gas 17.............................................................

5-8. Connecting Weld Cable 17...............................................................

5-9. Selecting Cable Sizes* 18................................................................

5-10. Installing And Threading Welding Wire 19...................................................

5-11. Motor Board (PC1) DIP Switch Settings 19..................................................

5-12. Display Board (PC22) DIP Switch Settings 20...............................................

SECTION 6 − OPERATION 22...................................................................

6-1. Controls 22............................................................................

6-2. Wire Speed Dual Schedule 23............................................................

SECTION 7 − MAINTENANCE & TROUBLESHOOTING 24.........................................

7-1. Routine Maintenance 24.................................................................

7-2. Overload Protection And Thermostat Protection 24...........................................

7-3. Cleaning Debris From Shielding Gas Filter Fitting 25..........................................

7-4. Troubleshooting 26......................................................................

7-7. Diagnostics 28.........................................................................

SECTION 8 − ELECTRICAL DIAGRAM 29........................................................

SECTION 9 − PARTS LIST 30...................................................................

WARRANTY

DECLARATION OF CONFORMITY

for European Community (CE marked) products.

MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).

Product/Apparatus Identification:

Product

Stock Number

FIELDPRO FEEDER, TWECO 301228

Council Directives:

• 2014/35/EU Low Voltage

• 2014/30/EU Electromagnetic Compatibility

• 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment

Standards:

• IEC 60974-5:2013 Arc welding equipment – Part 5: Wire feeders

• IEC 60974-10:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements

Signatory:

_____________________________________ ___________________________________________

David A. Werba

MANAGER, PRODUCT DESIGN COMPLIANCE

276011A

May 9, 2016

Date of Declaration

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

7

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

som 2015−09

DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex­plained in the text.

NOTICE − Indicates statements not related to personal injury.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.

Only qualified persons should install, operate, maintain, and
repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work
or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on

unit.

D Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid­able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt­age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install, ground, and operate this equipment according to

its Owner’s Manual and national, state, and local codes.

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym­bols and related instructions below for necessary actions to avoid the
hazards.

D Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

D Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D Frequently inspect input power cord and ground conductor for

damage or bare wiring – replace immediately if damaged – bare
wiring can kill.

D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be
present.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal. Disconnect cable for process not in
use.

D Use GFCI protection when operating auxiliary equipment in damp

or wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter weld­ing power sources AFTER removal of input power.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section
before touching any parts.

HOT PARTS can burn.

D Do not touch hot parts bare handed.
D Allow cooling period before working on

equipment.

D To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

OM-267043 Page 1

FUMES AND GASES can be hazardous.

)

Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.

D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.

D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch­person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath­ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.

D Wear an approved welding helmet fitted with a proper shade of

filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash,

glare and sparks; warn others not to watch the arc.

D Wear body protection made from durable, flame−resistant mate-

rial (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.

WELDING can cause fire or explosion.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear body protection made from durable, flame−resistant material

(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

D After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

D Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.

FLYING METAL or DIRT can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,
they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use

approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EMF
can affect Implanted Medical Devices.

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

D Wear approved ear protection if noise lev-

el is high.

Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot

burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not weld on containers that have held combustibles, or on

closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).

D Do not weld where the atmosphere can contain flammable dust,

gas, or liquid vapors (such as gasoline).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.

D Do not use welder to thaw frozen pipes.

OM-267043 Page 2

workpiece, and hot equipment can cause fires and

CYLINDERS can explode if damaged.

Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,

and fittings designed for the specific application; maintain them
and associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve. Do

not stand in front of or behind the regulator when opening the valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are long enough to

extend beyond opposite side of unit.

D Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

D Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94−110) when manu­ally lifting heavy parts or equipment.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

MOVING PARTS can injure.

D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards

closed and securely in place.

D Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

D Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.

D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and
local codes.

H.F. RADIATION can cause interference.

FLYING SPARKS can injure.

D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper
face, hand, and body protection.

D Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can injure.

D Keep away from moving parts.
D Keep away from pinch points such as drive

rolls.

WELDING WIRE can injure.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading
welding wire.

BATTERY EXPLOSION can injure.

D Do not use welder to charge batteries or jump

start vehicles unless it has a battery charging
feature designed for this purpose.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and
communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa­tion.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.

OM-267043 Page 3

1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: [phone],
website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:www.cga­net.com).

This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: [phone], website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: [phone], website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: [phone], website:
www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied pro­cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pace­makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con-
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:

1. Keep cables close together by twisting or taping them, or using a
cable cover.

2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.

5. Connect work clamp to workpiece as close to the weld as
possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire
feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom­mended.

OM-267043 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

7

Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.

2-1. Symboles utilisés

fre_som_2015−09

DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan­gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.

AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.

2-2. Dangers relatifs au soudage à l’arc

Les symboles représentés ci-dessous sont utilisés dans ce ma­nuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Sec­tion 2-5. Lire et observer toutes les normes de sécurité.

Seul un personnel qualifié est autorisé à installer, faire fonc­tionner, entretenir et réparer cet appareil.

Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.

UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.

Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est sous
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la
machine sont également sous tension lorsque l’alimen­tation est sur Marche. Dans le mode de soudage avec
du fil, le fil, le dérouleur, le bloc de commande du
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement
installé ou mis à la terre de manière incorrecte ou
impropre constitue un danger.

D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et

sans trous.

D S’isoler de la pièce à couper et du sol en utilisant des housses ou

des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.

D Ne pas se servir de source électrique à courant électrique dans les

zones humides, dans les endroits confinés ou là où on risque de
tomber.

D Se servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

D Si l’utilisation d’une source électrique à courant électrique s’avère

nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.

D D’autres consignes de sécurité sont nécessaires dans les condi-

tions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est re­commandée. En outre, ne pas travailler seul !

. Indique des instructions spécifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.

D Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-

stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir nor­mes de sécurité).

D Installez, mettez à la terre et utilisez correctement cet équipement

conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.

D Toujours vérifier la terre du cordon d’alimentation. Vérifier et

s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.

D En effectuant les raccordements d’entrée, fixer d’abord le conduc-

teur de mise à la terre approprié et contre-vérifier les connexions.

D Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques
chaudes.

D Vérifier fréquemment le cordon d’alimentation et le conducteur de

mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraî­ner la mort.

D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement

avec un câble distinct.

D Ne pas toucher l’électrode quand on est en contact avec la pièce,

la terre ou une électrode provenant d’une autre machine.

D Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide dou­blée.

D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-

champ les pièces endommagées. Entretenir l’appareil conformé­ment à ce manuel.

D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’assurer que tous les panneaux et couvercles sont correctement

en place.

D Fixer le câble de retour de façon à obtenir un bon contact métal-

métal avec la pièce à souder ou la table de travail, le plus près pos­sible de la soudure.

D Isoler la pince de masse quand pas mis à la pièce pour éviter le

contact avec tout objet métallique.

D Ne pas raccorder plus d’une électrode ou plus d’un câble de

masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.

D Utiliser une protection différentielle lors de l’utilisation d’un équi-

pement auxiliaire dans des endroits humides ou mouillés.

Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.

D Arrêter les convertisseurs, débrancher le courant électrique et

décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.

OM-267043 Page 5

LES PIÈCES CHAUDES peuvent

e

e

a

provoquer des brûlures.

D Ne pas toucher à mains nues les parties chaudes.
D Prévoir une période de refroidissement avant

de travailler à l’équipement.

D Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.

LES FUMÉES ET LES GAZ peuvent
être dangereux.

Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.

D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité
de fumées et de gaz auxquels est exposé le personnel.

D Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

D Lire et comprendre les fiches de données de sécurité et les instruc-

tions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.

D Travailler dans un espace fermé seulement s’il est bien ventilé ou

en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.

D Ne pas souder dans des endroits situés à proximité d’opérations

de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et for­mer des gaz hautement toxiques et irritants.

D Ne pas souder des métaux munis d’un revêtement, tels que l’acier

galvanisé, plaqué en plomb ou au cadmium à moins que le revête­ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.

LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudage génèr

des rayons visibles et invisibles intenses (ultraviolets
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur l
peau. Des étincelles sont projetées pendant le soudage.

D Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).

D Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

D Avoir recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.

D Porter un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.

LE SOUDAGE peut provoquer un

incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tels

que des réservoirs, tambours ou des conduites peut

provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des

pièces chaudes et des équipements chauds peut provoquer des incen­dies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un sur-

OM-267043 Page 6

chauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.

D Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.

D Ne pas souder dans un endroit là où des étincelles peuvent tomber

sur des substances inflammables.

D Se protéger et d’autres personnes de la projection d’étincelles et

de métal chaud.

D Des étincelles et des matériaux chauds du soudage peuvent

facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.

D Surveiller tout déclenchement d’incendie et tenir un extincteur à

proximité.

D Le soudage effectué sur un plafond, plancher, paroi ou séparation

peut déclencher un incendie de l’autre côté.

D Ne pas effectuer le soudage sur des conteneurs fermés tels que

des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).

D Ne pas souder là où l’air ambiant pourrait contenir des poussières,

gaz ou émanations inflammables (vapeur d’essence, par exemple).

D Brancher le câble de masse sur la pièce le plus près possible de la

zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provo­quant des risques d’électrocution, d’étincelles et d’incendie.

D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-

lées.

D En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

D Porter un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.

D Avant de souder, retirer toute substance combustible de vos po-

ches telles qu’un allumeur au butane ou des allumettes.

D Une fois le travail achevé, assurez−vous qu’il ne reste aucune

trace d’étincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et

NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.

D Lire et comprendre les fiches de données de sécurité et les instruc-

tions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.

DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.

la brosse en fil de fer, et le meulage génèrent des étincelles et des
particules métalliques volantes. Pendant la période de ref­roidissement des soudures, elles risquent de projeter du laitier.

D Porter des lunettes de sécurité avec écrans latéraux ou un écran

facial.

D Le soudage, l’écaillement, le passage de la pièce à

LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.

D Fermer l’alimentation du gaz comprimé en cas

de non utilisation.

D Veiller toujours à bien aérer les espaces confinés ou se servir d’un

respirateur d’adduction d’air homologué.

Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.

D Les porteurs de stimulateurs cardiaques et

autres implants médicaux doivent rester à
distance.

D Les porteurs d’implants médicaux doivent consulter leur médecin

et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.

LE BRUIT peut endommager l’ouïe.

Le bruit des processus et des équipements peut

affecter l’ouïe.

D Porter des protections approuvées pour les

oreilles si le niveau sonore est trop élevé.

LES BOUTEILLES peuvent exploser

si elles sont endommagées.

Les bouteilles de gaz comprimé contiennent du
gaz sous haute pression. Si une bouteille est

les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.

D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,

des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.

D Placer les bouteilles debout en les fixant dans un support station-

naire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.

endommagée, elle peut exploser. Du fait que

D Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec

une bouteille.

D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,

tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.

D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne

de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.

D Le couvercle du détendeur doit toujours être en place, sauf lorsque

la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.

D Utiliser les équipements corrects, les bonnes procédures et suffi-

samment de personnes pour soulever et déplacer les bouteilles.

D Lire et suivre les instructions sur les bouteilles de gaz comprimé,

l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU D’EXPLOSION.

D Ne pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.

D Ne pas installer l’appareil à proximité de pro-

duits inflammables.

D Ne pas surcharger l’installation électrique − s’assurer que

l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.

LA CHUTE DE L’ÉQUIPEMENT peut

provoquer des blessures.

D Utiliser l’anneau de levage uniquement pour

soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.

D Utiliser un équipement de levage de capacité suffisante pour lever

l’appareil.

D En utilisant des fourches de levage pour déplacer l’unité, s’assurer

que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.

D Tenir l’équipement (câbles et cordons) à distance des véhicules

mobiles lors de toute opération en hauteur.

D Suivre les consignes du Manuel des applications pour l’équation

de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement ; res-

pecter le cycle opératoire nominal.

D Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

D Ne pas obstruer les passages d’air du poste.

LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.

D Porter un écran facial pour protéger le visage et

les yeux.

D Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exé­cuter dans un endroit sûr lorsque l’on porte l’équipement ho­mologué de protection du visage, des mains et du corps.

D Les étincelles risquent de causer un incendie − éloigner toute

substance inflammable.

LES CHARGES ÉLECTROSTATI­QUES peuvent endommager les cir­cuits imprimés.

D Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antistatiques pour stocker, dé-

placer ou expédier des cartes de circuits imprimes.

Les PIÈCES MOBILES peuvent
causer des blessures.

D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

D Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de
soudage.

L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.

D Ne pas utiliser l’appareil de soudage pour

charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.

Les PIÈCES MOBILES peuvent
causer des blessures.

D S’abstenir de toucher des organes mobiles tels

que des ventilateurs.

D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de protection.

D Lorsque cela est nécessaire pour des travaux d’entretien et de dé-

pannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.

D Remettre les portes, panneaux, recouvrements ou dispositifs de

protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.

LIRE LES INSTRUCTIONS.

D Lire et appliquer les instructions sur les

étiquettes et le Mode d’emploi avant l’instal­lation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.

D N’utiliser que les pièces de rechange recommandées par le

constructeur.

D Effectuer l’installation, l’entretien et toute intervention selon les

manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.

OM-267043 Page 7

LE RAYONNEMENT HAUTE
FRÉQUENCE (H.F.) risque de
provoquer des interférences.

D Le rayonnement haute fréquence (H.F.) peut

pements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.

D Demander seulement à des personnes qualifiées familiarisées avec

des équipements électroniques de faire fonctionner l’installation.

D L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une distan­ce correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.

provoquer des interférences avec les équi-

D Veiller à ce que tout l’équipement de la zone de soudage soit com-

D Pour réduire la possibilité d’interférence, maintenir les câbles de

D Veiller à souder à une distance de 100 mètres de tout équipement

D Veiller à ce que ce poste de soudage soit posé et mis à la terre

D En cas d’interférences après avoir pris les mesures précédentes,

2-4. Proposition californienne 65 Avertissements

LE SOUDAGE À L’ARC risque de
provoquer des interférences.

D L’énergie électromagnétique risque de

provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.

patible électromagnétiquement.

soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).

électronique sensible.

conformément à ce mode d’emploi.

il incombe à l’utilisateur de prendre des mesures supplémentaires
telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
de travail.

Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal­formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: [phone],
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:www.cga­net.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060

2-6. Informations relatives aux CEM

Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après

utilisation.

Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: [phone], website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: [phone], website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: [phone], website:
www.cdc.gov/NIOSH).

Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les

OM-267043 Page 8

câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.

4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.

5. Connecter la pince sur la pièce aussi près que possible de la
soudure.

6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc­tion. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.

SECTION 3 − DEFINITIONS

3-1. Additional Safety Symbols And Definitions

. Some symbols are found only on CE products.

Warning! Watch Out! There are possible hazards as shown by the symbols.

Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.

Wear dry insulating gloves. Do not touch electrode (wire) with bare hand. Do not wear wet or damaged gloves.

Safe1 2012−05

Safe37 2012−05

Safe57 2012−05

Protect yourself from electric shock by insulating yourself from work and ground.

Disconnect input plug or power before working on machine.

Keep your head out of the fumes.

Use forced ventilation or local exhaust to remove the fumes.

Use ventilating fan to remove fumes.

Safe58 2012−06

Safe5 2012−05

Safe59 2012−05

Safe60 2012−06

Safe61 2012−06

Keep flammables away from welding. Do not weld near flammables.

Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

Safe62 2012−06

Safe63 2012−06

OM-267043 Page 9

Do not weld on drums or any closed containers.

?

Do not remove or paint over (cover) the label.

Drive rolls can injure fingers.

Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away.

Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.

Safe64 2012−06

Safe20 2012−05

Safe32 2012−05

Safe33 2012−05

Safe66 2012−06

3-2. Miscellaneous Symbols And Definitions

. Some symbols are found only on CE products.

Run-In Filter

I

1

Input Current Wire Feed Percent

Input

Constant Current

Trigger Hold Off Trigger Hold On

Read Instructions

U

Cold Jog (Inch) To-

wards Workpiece

Supplementary

1

Protector

Input Voltage Off On

Become trained and read the instructions before working on the
machine or welding.

Safe65 2012−06

A

I

Amperes

V

IP

Purge By Gas Power Connection

Constant Voltage Gas IN

Rated Welding

2

Current

Volts

Degree Of Protec-

tion

Increase

OM-267043 Page 10

SECTION 4 − SPECIFICATIONS

4-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located inside the door. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.

4-2. Unit Specifications

Type of

Input

Power

Open-Circuit/

Arc Voltage,

14 − 110

Volts DC

*See Section 4-3 for detailed wire type, size, and rated speed range

Welding

Power

Source

Type

Constant

Voltage (CV)

Or Constant

Current (CC)

DC Power

Source Only

Wire Feed

Speed*

25 − 800 ipm

(0.64 − 20.3

mpm) Depending

On Arc Voltage

Wire Diameter

Range

Solid Wire:

.023 - .052 in.

(0.6 To 1.3 mm)

Flux Cored:
.030 - 5/64 in.
(0.8 To 2 mm)

Input

Welding

Circuit
Rating

425 Amperes

At 60%

Duty Cycle

Max. Wire

Spool Capacity

45 lb (20.4 kg),

12 in. (304 mm)

4-3. Wire Type, Size, and Feed Speed Capability Table

Motor Speed Wire Type Wire Size Rated Speed Range*

Solid Wire:

.023 - .052 in.

Standard All

(0.6 To 1.3 mm)

Flux Cored:
.030 - 5/64 in.
(0.8 To 2 mm)

*Rated speed range per IEC 60974-5

50 to 780 ipm

(1.3 -19.8 mpm)

Overall

Dimensions

Length: 21 in.

(533 mm)

Width: 9 in.

(229 mm)

Height: 15-1/2 in.

(394 mm)

Weight

34.5 lb

(15.6 kg)

4-4. Gun Recommendation Table

Process Gun

FCAW(G) − Cored Wires

GMAW − Hard Wires

FCAW (S) − Self-Shielding Wires

PipeWorx 300-15

FC-1260
Dura-Flux

OM-267043 Page 11

4-5. Environmental Specifications

A. IP Rating

IP Rating

IP23

This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless

B. Information On Electromagnetic Compatibility (EMC)

! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−

voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con­ducted as well as radiated disturbances.

This equipment complies with IEC 61000-3-11 and IEC 61000-3-12.

C. China EEP Hazardous Substance Information

质量

China EEP Hazardous Substance Information

部

Component Name

(适)

(if applicable)

黄铜铜部

Brass and Copper Parts

装

Coupling Devices

装

Switching Devices

配

Cable and Cable
Accessories



Batteries

表SJ/T 11364规.

This table is prepared in accordance with China SJ/T 11364.
O:

表该质该部质量GB/T26572规限量要.

Indicates that the concentration of the Hazardous Substance in all homogeneous materials of the part is below the relevant threshold of China
GB/T 26572.

X:

表该质该部质量超GB/T26572规限量要.

Indicates that the concentration of the Hazardous Substance in at least one homogeneous material of the part is above the relevant threshold of
China GB/T 26572.

质

Hazardous Substance

铅

Pb

X

X O O O O O

O O X O O O

X O O O O O

X O



Hg

O O O O O

sheltered.

镉

Cd

O O O O

铬

Cr6

苯

PBB

IP23 2014−06

ce-emc 3 2014-07

苯醚

PBDE

限SJ/Z11388规.

The EFUP value of this EEP is defined in accordance with China SJ/Z 11388.

D. Temperature Specifications

Operating Temperature Range Storage Temperature Range

14 to 104 °F (−10 to 40°C) −4 to 131 °F (−20 to 55°C)

OM-267043 Page 12

EEP_2016−06

Temp_2016-07

SECTION 5 − INSTALLATION

5-1. Equipment Connection Diagram

1

3

9

10

! Turn Off wire feeder and

welding power source.

! Do not move or operate

equipment where it could tip.

1 Welding Power Source
2 Gas Hose
3 Weld Cable To Feeder
4 Work Cable To Workpiece
Weld cable and work cable connec-

tions to power source (DCEN/DCEP)
are dependant on wire type.

Power source is configured for
DCEP. To run DCEN manually swap
cables.

. Since feeder is not polarity sensi-

tive, there is no need for an elec­trode polarity switch.

5 Workpiece
6 Voltage Sensing Clamp

2

8

6

Connect voltage sensing clamp to
workpiece.

7 Gun
8 Gun Trigger Receptacle
9 Wire Feeder
10 Gas Cylinder
Use of shielding gas is dependant on

wire type.

. Shielding gas pressure not to ex-

4

ceed 100 psi (689 kPa).

7

5

258 966-A / Ref. 257 819-B

5-2. WCC (Weld Cable Control) Applications

. To take advantage of the WCC features, the FieldProt Feeder must be used with a PipeWorx 350 FieldProt power source.
5-3. Associating Wire Feeder To PipeWorx 350 FieldProt

1 Connect feeder to PipeWorx 350 FieldProt.
2 Do not strike an arc.
3 Feeder will display dashed lines and CCV until connected.
4 Once connected the feeder will display voltage.
5 Use voltage control on feeder to adjust weld voltage.
6 The voltmeter will alternate between preset voltage and open circuit voltage while idle or weld voltage at the wire feeder while welding.

. See Section 5-4 for detailed equipment setup.

OM-267043 Page 13

5-4. Equipment Setup

123

Acc

---

---

24.0

Associating the FieldProt Feeder to
the PipeWorx 350 FieldProt power
source:

1 Connect the feeder to the weld

circuit as you would a traditional
voltage−sensing wire feeder.
Feeder must be in CV mode to
work with FieldProt System
(See Section 6-1).

2 Turn on the welding power source

and wire feeder. The welding
power source will display the last
amperage set point and the wire
feeder will display three dashes
until connected. Allow 10−15
seconds for system to connect.

3 Once feeder is communicating

with power source, the power
source will display “Acc” and the
wire feeder will display preset
voltage and wire feed speed.

24.0

15.5

15.5

4 The preset welding voltage and

wire feed speed can now be
adjusted with the voltage control
on the wire feeder while not
welding.
While welding, the wire feeder
displays weld voltage at the
feeder. The power source displays
amperage from feeder while
welding and will display amperage
for 10 seconds after welding.

OM-267043 Page 14

255 911-A / Ref. 805 200-B / Ref.259 046-B

5-5. Installing Drive Rolls

Installing Drive Rolls:

1 Drive Roll Securing Nut
2 Drive Roll Carrier
Turn nut one click until lobes of nut

line up with lobes of drive roll carrier.
3 Drive Roll
Slide drive roll onto drive roll carrier.

Turn nut one click.
Repeat procedure for top drive roll.

Cleaning Drive Rolls:

Remove drive rolls, and clean
grooves using a wire brush.

Installing Drive Rolls

2

3

1

257 817-B

OM-267043 Page 15

5-6. Connecting Welding Gun And Voltage Sensing Clamp

5

2

5

1

Gun Locking Tab In Place

Gun Locking Tab Out Of Place

Internal Side View

3

4

! Turn Off wire feeder and

welding power source.
Stop engine on welding
generator.

! Weld voltage is present at

voltage sensing clamp
when wire feeder and
welding power source are
on. This condition exists
even if wire feeder light
and meters are off.

! Turn off wire feeder or

welding power source be­fore handling or moving
voltage sensing clamp.

1 Gun Securing Knob
2 Gun Block
3 Gun Power Pin
4 Power Pin Groove
5 Gun Locking Tab
Loosen gun securing knob, insert

gun power pin into gun block. Po­sition power pin as close as pos­sible to drive rolls without touch­ing. Align the gun power pin
groove with the gun locking tab.
Tighten gun securing knob.

If the gun power pin does not
have a groove, loosen knob to ro­tate the gun locking tab 180 de­grees. This prevents the the gun
locking tab from interfering with
the gun power pin when inserted
into the gun block. Insert the gun
power pin into the gun block. Pos­ition power pin as close as pos­sible to drive rolls without touch­ing them. Tighten gun securing
knob.

6 Gun Trigger Plug
7 Gun Trigger Receptacle
Connect gun trigger plug to gun

trigger receptacle.
See Section 6-2 to make wire

speed dual schedule connec­tions to gun trigger receptacle.

8 Voltage Sensing Clamp
Connect voltage sensing clamp

to workpiece.

8

OM-267043 Page 16

6

7

256 617-A / 257 810-B

5-7. Connecting Shielding Gas

3

2

4

Rear View

NOTICE − This feeder has a shield-
ing gas filter that requires special
attention when cleaning. See Sec­tion 7-3 for proper cleaning instruc­tions.

1 Gas Hose With 5/8-18

Right-hand Thread Fittings
(Customer Supplied)

. Tighten gas hose fitting to a

maximum of 100 in. lbs (12
N.m).

2 Shielding Gas Cylinder

. Shielding gas pressure not to

exceed 100 psi (689 kPa).

3 Valve
4 Flowmeter
Close valve on cylinder when fin-

ished welding.

1

5-8. Connecting Weld Cable

256 620-A

! Turn Off wire feeder and

welding power source. Stop
engine on welding
generator.

1 User-Supplied Weld Cable
Follow wire manufacturer’s recom-

mendations for weld cable polarity.
2 Male Connector
3 User-Supplied Female

Connector

Connect male and female
connectors.

1

3

2

256 621-A

OM-267043 Page 17

5-9. Selecting Cable Sizes*

! Turn off power before connecting to weld output terminals.
! Do not use worn, damaged, undersized, or repaired cables.

NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding***

100 ft (30 m) or Less

10 − 60%

Welding

Amperes

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 2x4/0 (2x120)
500 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x3/0 (3x95)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use

***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

Duty

Cycle

AWG (mm2)

60 − 100%

Duty Cycle

AWG (mm2)

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

10 − 100% Duty Cycle

AWG (mm2)

350 ft

(105 m)

400 ft

(120 m)

Ref. S-0007-L 2015−02

OM-267043 Page 18

5-10. Installing And Threading Welding Wire

1

Pull and hold wire; cut off end.

WOOD

6 in.

(150 mm)

Tighten

Clockwise

2

. Hold wire tightly

to keep it from
unraveling.

3

4

Installing Wire And Adjusting Hub
Tension

1 Retaining Nut
2 Hub Tension Adjustment Knob
Remove retaining nut, and install spool

so hub pin fits spool hole. Reinstall re­taining nut.

Adjust tension knob so only a slight force
is needed to turn spool.

. Do not over tighten tension knob. It

is not necessary to use any tools to
tighten the knob.

Threading Welding Wire

3 Pressure Adjustment Knob
4 Pressure Assembly
Lay gun cable out straight.

Open pressure assembly. Hold wire
tightly and cut off end. Guide wire
between alignment pins, into drive roll
grooves, and into gun liner.

Close pressure assembly and tighten
pressure adjustment knob enough to
feed wire. Press jog switch until wire
comes out of gun.

To set proper drive roll pressure, release
the pressure on the drive rolls by loosen­ing the pressure adjustment knob. Posi­tion gun at about a 45 degree angle, with
nozzle about two inches from a wooden
surface. While feeding the wire against
the wooden surface, increase the pres­sure to one half turn past the point where
the wire stops slipping. If the wire slips at
maximum hand-tight pressure, there
may be other problems. Check the gun
liner, spool tension, contact tip and drive
roll wear, as all these can cause wire
feeding problems.

Cut off wire, and close door.

Ref. 257 806-B

5-11. Motor Board (PC1) DIP Switch Settings

1 Motor Control Board PC1
2 DIP Switch SW1
3 LED5

. DIP switch SW1 is used to match the

performance of PC1 to the character­istics of the motor used in the feeder.
Setting SW1 as shown will help insure
that PC1 and motor are matched for
optimal performance.

Set switch positions 1 and 2 so the de­pressed section of both tabs are toward 1
and 2 as labeled on the switch. As shown
in illustration.

When feeder is powered up, LED 5 on the
motor control board will blink four times.
This blinking indicates everything is work-

RC111

1

OPEN

12

3

ing properly and the DIP switch is set cor­rectly.

After LED 5 is done blinking, it will be either
red or green. Red indicates that the feeder
is connected with electrode positive.
Green indicates feeder is connected with
electrode negative.

2

247 678-B

OM-267043 Page 19

5-12. Display Board (PC22) DIP Switch Settings

−−−−

OPEN−−−−

12345

−−−−OPE

N −−−−

12345

Accessing DIP Switch
1 Lens
DIP switch is located under the lens

next to the displays.
2 Lens Screws
Remove three screws.
Loosen upper right hand screw to

rotate lens enough to access DIP
switch.

Replace three screws removed
earlier.

Tighten upper right hand screw.

. The two upper screws must

engage the backing plate to
properly secure the front panel.

Factory DIP
switch settings
when displaying
inches per
minute

Factory DIP
switch settings
when displaying
meters per
minute

2
1

−−−−OPE

12345

N−−−−

−−−−OPEN−−−

12345

−

OM-267043 Page 20

DIP Switch Settings:
Display Hold OFF − Set switch 1 so the depressed section is toward OPEN as labeled on the switch.

Displays will not hold values. The voltage displayed while welding is an average reading over a time span of 6 to 8 sec­onds. If the weld time is less than 8 seconds, the voltage displayed may not be accurate.

Display Hold ON (Factory Default) − Set switch 1 so the depressed section is toward 1 as labeled on the switch.
Displays will hold their last value for five seconds after the trigger is released. The voltage displayed while welding is

an average reading over a time span of 6 to 8 seconds. If the weld time is less than 8 seconds, the voltage displayed
may not be accurate.

−−−−OPEN−−−

12345

Display Amperage − Set switch 2 so the depressed section is toward OPEN as labeled on the switch.
Wire Speed / Amps Display will display Amps while welding and Wire Speed while not welding. If the hold function

is enabled, Amps will be displayed during hold also.

−

−−−−OPEN−−−

12345

Do Not Display Amperage (Factory Default) − Set switch 2 so the depressed section is toward 2 as labeled
on the switch.

Wire Speed / Amps Display will display only Wire Speed.

−

−−−−

12345

OPEN−−−−

−−−−OPEN−−−

12345

Wire Speed - Meters Per Minute − Set switch 3 so the depressed sections are toward OPEN as labeled on the
switch.

Displays Wire Speed in Meters per Minute.

Wire Speed - Inches Per Minute − Set switch 3 so the depressed sections are toward 3 and 4 as labeled on the
switch.

Displays Wire Speed in Inches per Minute.

−

−−−−

12345

OPEN−−−−

No Wire Feeding While Association OFF (Factory Default) − Set switch 4 so the depressed section is toward
4 as labeled on the switch.

This will allow wire to feed when the trigger is pulled and association is not expected to take place, such as when
using the feeder with a non−WCC power source or if a WCC power source is to be used in the STICK process
with the feeder CC/CV switch in CC.

OPEN−−−−

−−−−OPEN−−−

−

−−−−
OPEN−−−−

−−−−

12345

12345

12345

No Wire Feeding While Association ON − Set switch 4 so the depressed section is toward OPEN as labeled
on the switch.

This will prevent wire from feeding while the process of association takes place.

Display Feeder Information − Set switch 5 so the depressed section is toward OPEN as labeled on the switch.
With switch in ON position, at feeder power up, feeder will display various sets of information. Each set of informa-

tion will be displayed for three seconds.

Display Board (PC22) Software Part Number −

Top display will show the first three digits, bottom display will show last three digits of the Display board (PC22)
software revision level.

Motor Board (PC1) Software Part Number −

Top display will show the first three digits, bottom display will show last three digits of the Motor board (PC1) soft­ware revision level.

Accumulated Weld Time −

This is the time the feeder has actually been used for welding. This information will be displayed in two halves.
First being years and days, second in hours and minutes. Top display will show years/hours, bottom display will
show days/minutes.

Do Not Display Feeder Information (Factory Default) − Set switch 5 so the depressed section is toward 5 as
labeled on the switch.

Feeder information is not displayed.

Ref. 805 200-B

OM-267043 Page 21

6-1. Controls

SECTION 6 − OPERATION

76

10

4

5

Front Panel With Meters

1

2

3

8

Internal Control Panel

9

1 Voltmeter
If feeder displays dashed lines and OCV,

feeder is trying to associate with the
PipeWorx 350 FieldProt welding power
source. See Section 5-4 for details.

When the wire feeder is associated with the
PipeWorx 350 FieldProt welding power
source the voltmeter will alternate between
preset voltage and open circuit voltage
while idle. While welding the feeder will
display the actual weld voltage at the wire
feeder.

Whether the wire feeder is associated or
not the voltage displayed while welding is
an average reading over a time span of 6 to
8 seconds. If the weld time is less than 8
seconds, the voltage displayed may not be
accurate.

2 Wire Speed / Amperage Meter
Displays wire speed in Inches per Minute.

To display wire speed in Meters per Minute
(see Section 5-12).

Amperage displayed at the feeder is
approximate. Refer to power source for
actual amperage. To display Amperage
(see Section 5-12).

3 Wire Speed Control
Use control to adjust wire speed. Maximum

wire speed may be limited by arc voltage.

4 Voltage Control
Used to adjust output voltage of welding

power source when wire feeder is
associated with a WCC compatible welding
power source or WCC Control. Voltage
may be adjusted while not welding.

Voltage control has no function when the
wire feeder is not associated with a WCC
compatible welding power source or WCC
Control.

5 Power Control Switch
6 Soft Start Switch
The Soft Start feature provides a smooth

start during most weld conditions. When the
trigger is pulled, the wire speed is
approximately 50% of the weld wire speed,
as set by the wire speed control knob. After
an arc is established, the wire speed
increases to the weld wire speed.

When using small diameter wire, or with
inverter power sources, it may be
necessary to turn switch off to obtain
smooth starts.

7 CC/CV Switch
Use switch to match feeder with the output

of the power source.

Internal Side View

Ref. 273 255-B

. The feeder will not associate with a

WCC Control or power source if the
switch is set to CC.

8 Trigger Hold Switch
Trigger hold allows operator to weld without

holding gun trigger.
To use trigger hold function, place trigger

hold switch in the ON position.
The operator must hold the trigger for a

minimum of 2 seconds, but no longer than
6 seconds before releasing it. Welding will
continue when trigger is released.

To stop welding, press and release the
trigger.

9 Jog/Purge Switch
Pressing the Jog switch allows the operator

to jog wire without energizing the contactor
or gas valve.

Pressing the Purge switch allows the
operator to purge gas lines before welding
and to preset gas flow rate at the flowmeter.

After adjusting the switches, close and
latch the door before welding.

10 Polarity Indicators
Indicate whether feeder is connected to the

welding power source Electrode Positive
(DCEP) or Electrode Negative (DCEN).

OM-267043 Page 22

6-2. Wire Speed Dual Schedule

Weld Gun With Internal Mounted
Dual Schedule Switch

1

2

Wire Speed Dual Schedule allows the oper­ator to switch between standard wire speed
and a reduced wire speed. When activated,
the reduced wire speed will be 87.5% of the
standard wire speed. Wire Speed Dual
Schedule may be activated any time before
or during the weld by using a gun with an in­ternally mounted dual schedule switch, or a
gun with an added dual schedule switch. If
the feeder is equipped with Wire Speed
Meter it will display the active wire speed,
whether it is standard wire speed or reduced
wire speed.

Weld Gun With Internal Mounted Dual
Schedule Switch Comparable To

PipeProR Dura−Fluxt Gun.
1 Gun Trigger Receptacle
2 Gun Trigger Plug
Connect gun trigger plug to gun trigger

receptacle.

Weld Gun With External Mounted
Dual Schedule Switch

3

4

Weld Gun With External Mounted Dual
Schedule Switch Comparable To

DSS−9−15 (071833)
3 Gun Trigger Receptacle
4 Dual Schedule Plug
5 Dual Schedule Switch Receptacle
6 Gun Trigger Plug
Connect gun trigger plug to dual schedule

switch receptacle . Connect dual schedule
plug to gun trigger receptacle.

5

6

263 909-A / 263 911-A

OM-267043 Page 23

SECTION 7 − MAINTENANCE & TROUBLESHOOTING

7-1. Routine Maintenance

Every

3

Months

Every

6

Months

! Disconnect power

before maintaining.

n = Check Z = Change ~ = Clean l = Replace
* To be done by Factory Authorized Service Agent

l Damaged Or Unreadable Labels l Damaged Gas Hose

n l Cracked Cables And Cords

n ~ Drive Rolls ~ Blow Out Or Vacuum Inside

. Maintain more often

during severe conditions.

7-2. Overload Protection And Thermostat Protection

CB1

Internal Side View

! Turn Off wire feeder and

welding power source. Stop
engine on welding
generator.

1

1 Supplementary Protector CB1
CB1 protects wire feeder from over-

load. Correct problem and reset
CB1.

Close and latch door.

Thermostat Protection

Unit has internal thermostat protec­tion and will not feed wire if over­heating occurs (see Section 7-4).

OM-267043 Page 24

Ref. 257 794-B

7-3. Cleaning Debris From Shielding Gas Filter Fitting

Rear View of Feeder

! Disconnect power before

maintaining.

1 Shielding Gas Filter Fitting
Remove fitting from gas valve on

back panel of feeder.
Blow compressed air through the

threaded male end of fitting to dis­lodge debris from internal mesh
screen.

. Replace fitting if blowing com-

pressed air through fitting does
not clear obstructions.

Reinstall fitting into gas valve.
Tighten fitting to 250 in. lbs (28 N⋅m).

1

Tools Needed:

3/4 in.

256 623-A

OM-267043 Page 25

7-4. Troubleshooting

Trouble Remedy

Wire does not feed; open-circuit voltage
available.

Wire feeds erratically.

Check power switch S1 and connections, replace if necessary.

Check supplementary protector CB1. Reset CB1.

Unit overheated. Allow unit to cool.

Check sensing lead connection.

Check gun trigger plug connection.

Check gun trigger. See gun Owner’s Manual.

Check Resonant Coupler PC23 and connections, replace if necessary.

Have Factory Authorized Service Agent check Control board PC1.

Readjust hub tension (see section 5-10).

Readjust drive roll pressure (see section 5-10).

Clean or replace dirty or worn drive roll (see Section 5-5).

Remove weld spatter around nozzle opening.

Replace contact tip or liner (see gun Owner’s Manual).

Change to correct size and type drive roll (see Section 5-5)
Check that DIP switches on Motor Control Board (PC1) are set correctly (see section 7-5)

Have Factory Authorized Service Agent check control board PC1.

Motor runs slowly. When soft start is on, motor will run slow until weld current is sensed by HD1.

Readjust hub tension (see Section 5-10).

Check if wire speed dual schedule switch is activated (if applicable, see Section 6-2)

Check and replace contact tip or liner if necessary (see gun Owner’s Manual).
Check that DIP switches on Motor Control Board (PC1) are set correctly (see section 7-6)

Have Factory Authorized Service Agent check Control board PC1.

Unit does not switch out of Soft Start. Check transducer HD1 and connections, and replace if necessary.

Wire feeds when Jog switch is pressed
but not when gun trigger is pressed.

Wire stubbing on low end using a con­stant current power source or feeder re­sets.

Gas does not flow or does not stop flow­ing; wire feeds.

Wire remains energized after trigger is
released.

Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owner’s
Manual.

Have Factory Authorized Service Agent check Control board PC1.

Ensure that CC/CV switch in feeder is in CC position (see Section 6-1).

Increase power source inductance setting if available.

Increase output setting of power source or decrease wire feed speed.

Clear blockage in gas hose or replace hose.

Clear blockage in welding gun.

Clear blockage in filter (see Section 7-3).

Check gas valve.

Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary.

Have Factory Authorized Service Agent check Control board PC1.

Check setting of trigger hold switch.

Check contactor W1 to see if contacts are frozen closed.

OM-267043 Page 26

Trouble Remedy

Gun trigger is pressed, gas does not
flow, wire is not energized, wire feeds.

Display on Meter Board PC22 does not
light.

Segments on Meter Board PC 22 are
missing.

Weld voltage on Meter Board PC 22 is
not accurate.

While not welding − Voltage display al-
ternates between three dashes and
open circuit voltage.

While not welding − Voltage display
alternates between CC and open circuit
voltage.

Weld amperage on Meter Board PC22 is
not accurate.

If a welding arc is not established in 3 seconds after the gun trigger is activated, the unit will feed wire
without energizing the contactor or gas valve. The unit will feed approximately 35 feet (10.7 meters) of
wire, then stop feeding. This is to prevent complete despoolling of the wire, as in the case of a damaged
gun.

Have Factory Authorized Service Agent check Control board PC1.

Replace Meter Board PC22.

Replace Meter Board PC22.

Weld voltage on Meter Board PC22 will show weld voltage at the feeder. Due to voltage drops in the weld
cables, weld voltage at the feeder will not match weld voltage at the welding power source. Due to aver­aging of weld voltage, if weld time is less than 8 seconds the displayed weld voltage at the feeder may
not be accurate.

Check Motor Control PC1 and connections, replace if necessary.
This is normal when unit is connected to a Non−WCC compatible power source (see Section 6-1).

Unit is connected to but not associated to a WCC control or WCC compatible power source
(see Section 5-3).

This is normal when the CC/CV switch is set to CC mode (see Section 6-1).

Amperage displayed at feeder is approximate. Refer to power source for actual amperage
(see Section 5-12)

Check DIP switch settings on Meter Board PC22 (see Section 5-12).

Software and weld time information on
Meter Board PC22 is not accurate.

When associated to a WCC control or
WCC compatible power source −
Voltage displayed on feeder does not
match voltage on power source.

Feeder will not associate to a WCC con­trol or WCC compatible power source.

Check transducer HD1 and connections, and replace if necessary.

Check Motor Control PC1 and connections, replace if necessary.

Check DIP switch settings on Meter Board PC22 (see Section 5-12).

Check Motor Control PC1 and connections, replace if necessary.

Preset voltages between the feeder and welding power source should be within 0.5 volt of each other.

When associated to a WCC control, verify that the WCC control is configured properly
(see WCC control owner’s manual).

While welding the voltage displayed at the feeder is the weld voltage at the feeder. The voltage displayed
at the power source is the weld voltage at the power source. These two voltages will not match due to
voltage drops in the weld cables.

Due to averaging of the weld voltage, if weld time is less than 8 seconds the displayed weld voltage at
the feeder may not be accurate.

Check Motor Control PC1 and connections, replace if necessary.

Follow equipment setup procedure (see Section 5-4).

CC/CV switch must be set to CV to associate to WCC control or WCC compatible power source
(see Section 6-1)

Ensure that the WCC compatible power source Mode Switch is set to V−SENSE FEEDER
(see Section 5-4).

OM-267043 Page 27

7-7. Diagnostics

Error Indicators

Shown On Display RED LED on Motor Board PC1 Error

HLP 11 1 Blink Communication Error

HLP 12 2 Blinks Trigger Error

HLP 13 3 Blinks Tach Error

HLP 14 4 Blinks Motor

Overload Error

HLP 15 5 Blinks Bus Bar

Overheat Error

Error Indications - Error conditions are indicated by a “HLP” message on the display, or by the blinking of the Red LED on Motor Board PC1. To
view the Red LED, turn Off power source, remove shroud, and turn power source On. The number of blinks in this period indicates the type of
error. If an error condition does not exist on the motor board, the Red LED is on steady.

Communication Error - The communication error occurs 2.5 seconds after a loss of communication between the motor board and the meter
board. The user may continue to weld with this error. The error may be cleared by turning power Off, waiting a minimum of two seconds, and
turning power On.

Trigger Error - The trigger error occurs if the user has feed approximately 35 feet (10.7 meters) of wire without striking an arc. The error may be
cleared by releasing the trigger.

Motor Overload Error - The motor overload error can indicate that the motor has been drawing too much current for too long, To remedy this,
reduce the wire feed speed or the wire feeder torque load/duty cycle. The error may be cleared by turning power Off, waiting a minimum of two
seconds, and turning power On.

Bus Bar Overheat Error - The bus bar overheat error can be caused by the arc drawing too much current for too long. To remedy this, reduce
the weld amperage or duty cycle.

Tach Error - May indicate motor is overloaded. If a tach error occurs, feeder will continue to function. When the trigger is released, a tach error
will be indicated on the front panel, or red LED blinks on Motor Control Board (PC1). The tach error will be cleared when the feeder is retriggered.
If error persists, have feeder serviced. Tach error may also be generated if DIP switch SW1 on Motor Control Board (PC1) is set incorrectly (See
Section 5-11).

Notes

OM-267043 Page 28

SECTION 8 − ELECTRICAL DIAGRAM

Figure 8-1. Circuit Diagram For Wire Feeder

257 274-C

OM-267043 Page 29

SECTION 9 − PARTS LIST

. Hardware is common and

not available unless listed.

15

6

4

5

5

1

19

20

21

22

24

23

25

18

26

37

38

27

39

44

17

30

51

29

31

16

36

28

34

41,42

43

32

49
40

33

52

35

48

47

46

45

10

789

50

3

12
13

14

11

2

OM-267043 Page 30

257 072-B

Figure 9-1. Complete Assembly

Item
No.

Diagram
marking

Part
No. Description Quantity

Figure 9-1. Complete Assembly

1 Fig 9-2 Panel Assembly Front 1.................. .. ............................................

2 Fig 9-3 Drive Assembly, Wire 1.................. .. ............................................

3 S2 216295 Switch, Rocker Spdt .4VA 28VDC (On)-Off-(On) .187T 1........ ...... .. ...............

4 +258330 Case, Feeder Machined Blk w/Inserts 12VS WCC 1................. .. ...................

5 258965 Label, Warning/Miller/FieldPro Feeder 2.................. .. .............................

252393 Label, Warn Gen Precaution Suitcase CE/Domestic 1.................... .. ..................

6 208015 Handle, Rubberized Carrying 1.................. .. .....................................

7 CB1 083432 Supplementary Pro, Man Reset 1P 10A 250VAC Frict 1........ ..... .. ................

8 257782 Panel, Inner Snap-in Breaker 1.................. .. .....................................

9 256201 Plate, Inner WCC Snap-in Breaker 1.................. .. .................................

10 S3, S4, S6 217932 Switch, Rocker SPST .4VA 28VDC On-None-Off .187 Ter 3.... .. .. ............

11 PC23 257190 Module, WCC Series Resonant L-C Coupler 1...... .... .. ........................

12 252177 Chassis, Control Box 1................. .. ............................................

13 256594 Grommet, Scr No 8/10 Panel Hole .309 x .315 .125H 2................. .. ................

14 256595 Grommet, Scr No 8/10 Panel Hole .270 x .290 .062H 5................. .. ................

15 222103 Support, Spool 1................. .. ..................................................

16 222294 Clip, Wire/Cord .380 Bundle .250Hole .105 Thk Blk 2................. .. ..................

17 +252186 Shroud, Wire 1................ .. ...................................................

18 196956 Label, Warning Electric Shock And Pinch Wordless 1................. .. ..................

19 235607 Nut, Hub 1................. .. .......................................................

20 237843 Knob, Brake Adjust 1................. .. ..............................................

21 172918 Spring 1................. .. .........................................................

22 231211 Washer, Anti-Turn 2................. .. ...............................................

23 235608 Hub, Spool 12 In. 1................. .. ................................................

24 058424 Washer, Fiber (Brake) 1................. .. ............................................

25 210133 Bracket, Capacitor Support SC12 1................. .. ..................................

26 C1, C2 200606 Capacitor, Elctlt 1200 Uf 300 VDC Can 1.39 Dia 2..... .... .. .....................

27 207678 Insulator, Capacitors 1................. .. .............................................

28 211989 Fitting, w/Screen 1................. .. ................................................

29 215980 Bushing, Strain Relief .709/.984 ID x 1.375 Mtg Hole 1................. .. .................

30 600324 Cable, Weld Cop Strd No 4/0 Epdm Jkt 22 in.................. .. ..........................

31 258340 Clip, Snap In .250 Hole .062−.857 Pnl Thk Blk 1................. .. .......................

32 252194 Insulator, Rear Panel 1................. .. ............................................

33 252196 Bushing Gas Valve Opening 1................. .. ......................................

34 234126 Nut, Conduit 1.000 NPT Knurled 1................. .. ..................................

35 253430 Terminal, Connector Friction 0.406 ID 1................. .. ..............................

36 PC1 238276 Circuit Card Assy, Motor Control w/Program 1....... ..... .. ........................

37 HD1 218339 Transducer, Current 600A Module Supply V +5V 1....... ..... .. ....................

38 183387 Washer, Cone .380 ID x .860 OD x.109T Stl Pld 4000 lbs 2................. .... ...........

39 W1 255627 Contactor Assembly, (Includes) 1....... ..... .. ...................................

40 PLG5 201665 Housing Plug+Skts, (Service Kit) 1...... .... .... ................................

41 183387 Washer, Cone .380 ID x .860 OD x.109T Stl Pld 4000 lbs 2................. .... ...........

42 232295 Nut, M10−1.5 17Hex 10H Stl 2................. .... ....................................

43 TP1, TP2 230471 Thermostat, NC Open 140C Close 110C Snap Action 2.... ... .... ..............

44 252252 Bracket, Mtg Contactor 1................. .. ...........................................

45 134834 Hose, SAE .187 ID x .410 OD x Coil 20 in.................. .. .............................

46 149332 Clamp, Hose .405 − .485 Clp Dia Slfttng Olive Dra 2................. .. ...................

47 GS1 226819 Valve, 12VDC 1Way .750−14 Thd 2mm Orf 100PSI 1....... ..... .. ..................

48 252254 Bracket, Gas Valve 1................. .. ..............................................

49 220805 Nut, 750-14 Knurled 1.68Dia .41H Nyl 1................. .. ..............................

50 147195 Nut, 375−27 .54Hex .25H Nyl Flange .62D 1................. .. ..........................

51 242250 Conn,Tw Lk Insul Male(Tweco/Lenco Type) Hd 3/0-4/0 1................. .. ...............

52 255736 Core, Ferrite EMI Snap-on .393 ID x .877 OD x 1.290 L 1................. .. ..............

OM-267043 Page 31

Item

y

No.

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Diagram
marking

PLG3, 25 115093 Housing Plug+Skts, (Service Kit) 2....... ... .. ..................................

PLG4 131054 Housing Rcpt+Skts, (Service Kit) 1......... .... .. ..................................

PLG5 201665 Housing Plug+Skts, (Service Kit) 1......... .... .. ..................................

PLG7 130203 Housing Plug+Skts, (Service Kit) 1......... .... .. ..................................

PLG8 115091 Housing Plug+Skts, (Service Kit) 1......... .... .. ..................................

PLG9, 21 131055 Housing Rcpt+Skts, (Service Kit) 2....... ... .. ..................................

PLG10 131052 Housing Rcpt+Skts, (Service Kit) 1........ .... .. ..................................

PLG17 222397 Housing Plug+Skts, (Service Kit) 1........ .... .. ..................................

PLG22 115092 Housing Plug+Skts, (Service Kit) 1........ .... .. ..................................

PLG23 208730 Housing Plug+Skts, (Service Kit) 1........ .... .. ..................................

PLG24 131204 Housing Plug+Skts, (Service Kit) 1........ .... .. ..................................

PLG111 256953 Housing Plug+Skts, (Service Kit) 1........ ... .. ..................................

RC25 131059 Housing Plug+Pins, (Service Kit) 1......... .... .. ..................................

Part
No. Description Quantit

Figure 9-1. Complete Assembly (Continued)

Notes

OM-267043 Page 32

. Hardware is common and

not available unless listed.

13

16

14

17

5

2

6

9

15

1

10

9

8

3

4

7

11

12

8

Figure 9-2. Front Panel Assembly with Meters

Item
No.

Dia.
Mkgs

Part
No. Quantity

Description

.

Figure 9-2. Front Panel Assembly with Meters (Figure 9-1 Item 1)

1 S1 111997 Switch, Rocker SPST 10A 250VAC On−Off Visi Red Rock 1.. ..... ..... .. .............

2 Nameplate, SC WCC HDD Lower (Order By Model And Serial Number) 1.. ........................ ..

3 271367 Label, Bezel WCC 1.. .............. .. ................................................

4 271368 Lens, Suitcase WCC 1.. .............. .. ..............................................

5 257187 Panel, Front WCC 1.. .............. .. ................................................

6 229274 Knob, Tapered 1.00 / 1.5 Dia x .90H x .25 ID 2.. .............. .. .........................

7 PC22 271371 Circuit Card Assy, WCC Meter Suitcase HDD 1.. ... .... .. .........................

8 252262 Cable, Trigger 25 in. w/ Strain Relief (Includes) 1.. .............. .. .......................

9 139042 Bushing, Strain Relief .270/.470 ID x .804 Mtg Hole 2.. .............. .... ..................

10 PLG6 115094 Housing Plug+Skts, (Service Kit) 1.. .. .... .... ..................................

11 048834 Conn, Circ Cpc Clamp Str Rlf Size 11 .329 OD 1.. ............. .... ......................

12 RC2 080328 Rcpt w/Skts, Free Hanging 1.. ... ..... .... .......................................

604571 Cable, Port No 18 4/C Type Sjo Nprn Jkt Re 25 in.................... .... ......................

13 252212 Cable, Sensing w/Strain Relief (Includes) 16 Ft.. ............. .. ...........................

14 208820 Clamp, Work 1.. ............. .... ...................................................

15 258058 Wire, Strd 10GA Blk 600V 125C 105 x 30 POE .216 OD 16 Ft.. ............. .... ............

16 261163 Label, Warning Electric Shock/Volt Sense Clamp 1.. ............. .... ....................

17 265942 Panel, Front WCC 1.. ............. .... ...............................................

257 793-B

To Maintain The Factory Original Performance Of Your Equipment, Use Only Manufacturer’S Suggested
Replacement Parts. Model And Serial Number Required When Ordering Parts From Your Local Distributor.

OM-267043 Page 33

. Hardware is common and

not available unless listed.

44

45

42

25

24

13

33

32

15

18

17

16

19

31

30

14

20

29

34 35

38

13

39

10

12

21

36

40

41

11

22

2

10

9

8

23

3

26

7

6

1

5

4

27

43

46

OM-267043 Page 34

37

28

257 016-B

Figure 9-3. Drive Assembly, Wire

Item
No.

Dia.
Mkgs

Part
No. Quantity

Description

.

Figure 9-3. Drive Assembly, Wire (Figure 9-1 Item 2)

1 M1 252214 Motor, Right Angle 24VDC 1........ ..... .. ........................................

2 PLG4 131054 Housing Plug+Skts, (Service Kit) 1....... .... .. ..................................

3 252229 Insulator, Motor/Drive/Tach 1.................. .. .......................................

4 149332 Clamp, Hose .405 − .485 Clp Dia Slfttng Olive Dra 1.................. .. ...................

5 134834 Hose, SAE .187 ID x .410 OD x coil 20 In................... .. ..............................

6 263858 Module, Tach Service 1.................. .. ............................................

7 231181 Screw, 004−40 x .37 Soc Hd−Hex Stl Pld 4.................. .. ...........................

8 174610 Screw, M 6−1.0 x 20 Soc Hd Button Cap Blk 3.................. .. ........................

256035 Casting Assembly, Drive (Includes) 1.................... .. ................................

9 079634 Pin, Hinge 1.................. .... ....................................................

10 151828 Pin, Cotter Hair .042 x .750 3................. .... .....................................

11 252235 Lever, Mtg Pressure Gear Machined 1................. .... .............................

12 252238 Stand−Off, Drive Roll Carrier 1................. .... ....................................

13 172075 Carrier, Drive Roll w/Components 24 Pitch 2................. .... ........................

14 228562 Screw, 006−32x .25 Pan Hd−Phl w/Ext Washer (Sems) Stl 1................. .... ..........

15 196895 Knob, Pressure 1................. .... ................................................

16 252243 Spring, Cprsn Big 1................. .... ..............................................

17 241856 Cup, Spring 1................. .... ...................................................

18 085244 Washer, Cupped .328 ID x .812 OD x 16 ga x.125 Lip 1................. .... ..............

19 225718 Fastener, Pinned 1................. .... ..............................................

20 010224 Pin, Spring CS .187 x 1.000 1................. .... .....................................

21 222159 Spring, Torsion 1................. .... ................................................

22 253655 Insulator, Screw Motor 3................. .... .........................................

23 253513 Housing, Wire Drive 1................. .... ............................................

24 166072 Spacer, Gear 1................. .... ..................................................

25 602009 Screw, 250−20 x1.25 Soc Hd−Hex Gr 8 Pln 1................. .... .......................

26 264611 O−Ring, .187 ID x .312 OD x .063 CS 75 Duro Fluor 1................. .... ...............

27 144172 Ftg, Hose Brs Barbed M 3/16 TBG x .250-20 1................. .... ......................

28 263877 Wire Drive Bus Bar (Service Kit) (Includes) 1................. .... ........................

259857 Screw, 375−16 x .87 Hex Hd−Pln Gr5 Pld Blk 1.................... ...... ....................

231223 Nut, 375−16 .56Hex .34H Stl Pld Clr 1.................... ...... ............................

183387 Washer, Cone .380 ID x .860 OD x .109T Stl Pld 4000lbs 2.................... ...... .........

252232 Bolt, Crg Stl .375−16 x 1.000 Gr5 Pl Fnsh 1.................... ...... .......................

29 252230 Grommet, Motor Shaft 1................. .. ...........................................

30 252786 Drive, Pinion 10mm Shaft 1................. .. ........................................

31 252220 Key, Stl 3mm/3mm x 10mm 1................. .. .......................................

32 602237 Washer, Flat .172 ID x 0.500 OD x .048t Stl Pld Blk 1................. .. ..................

33 174609 Screw, M 4− .7 x 12 Cheese Hd Blk Din 84 1................. .. .........................

34 133308 Ring, Rtng Ext .375 Shaft x .025 Thk 1................. .. ...............................

35 168825 Drive, Pinion Sntr 22T 24P .376 Bore 1................. .. ..............................

36 252222 Screw, 010−32 x .75 Soc Hd−Hex Stl Gr8 Pld Lkg Patch 4................. .. ..............

37 124778 Knob, T 2.000 Bar w/.312-18 Stud 1.000 Lg Plstc 1................. .. ....................

38 237188 Lock, Pin Power 1................. .. .................................................

39 234074 Clamp, Pin Power 1................. .. ...............................................

40 234073 Pin, Hinge 1................. .. ......................................................

41 151828 Pin, Cotter Hair .042 x .750 3................. .. .......................................

42 252785 Cover, Gear 1................. .. ....................................................

43 143360 Screw, 008−32 x .50 Pan Hd−Phl Stl Pld Blk 3................. .. ........................

44 253404 Screw, 008−32 x .75 Soc Hd−Hex Stl Pld Lkg Patch 1................. .. .................

45 252322 Block, Wire Inlet Guide 1................. .. ...........................................

46 252323 Pin, Wire Inlet Guide 2................. .. .............................................

To Maintain The Factory Original Performance Of Your Equipment, Use Only Manufacturer’S Suggested
Replacement Parts. Model And Serial Number Required When Ordering Parts From Your Local Distributor.

OM-267043 Page 35

Table 9-1. Drive Roll

. Base Selection Of Drive Rolls Upon The Following Recommended Usages:

1. V-Grooved Rolls For Hard Wire.

2. U-Grooved Rolls For Soft And Soft Shelled Cored Wires.

3. U-Cogged Rolls For Extremely Soft Shelled Wires (Usually Hard Surfacing Types).

4. V-Knurled Rolls For Hard Shelled Cored Wires.

5. Drive Roll Types May Be Mixed To Suit Particular Requirements (Example: V-Knurled Roll In Combination With U-Grooved).

Wire Diameter Drive Roll (2 Required)

Fraction Decimal Metric Part No. Type

0.023−0.025 in. 0.023−0.025 in. 0.6 mm 087130 V−Grooved

0.030 in. 0.030 in. 0.8 mm 053695 V−Grooved

0.035 in. 0.035 in. 0.9 mm 053700 V−Grooved

0.040 in. 0.040 in. 1.0 mm 053696 V−Grooved

0.045 in. 0.045 in. 1.2 mm 053697 V−Grooved

0.052 in. 0.052 in. 1.3 mm 053698 V−Grooved
1/16 in. 0.062 in. 1.6 mm 053699 V−Grooved

0.035 in. 0.035 in. 0.9 mm 072000 U−Grooved

0.045 in. 0.045 in. 1.2 mm 053701 U−Grooved

0.052 in. 0.052 in. 1.3 mm 053702 U−Grooved
1/16 in. 0.062 in. 1.6 mm 053706 U−Grooved
5/64 in. 0.079 in. 2.0 mm 053704 U−Grooved

0.035 in. 0.035 in. 0.9 mm 132958 V−Knurled

0.045 in. 0.045 in. 1.2 mm 132957 V−Knurled

0.052 in. 0.052 in. 1.3 mm 132956 V−Knurled
1/16 in. 0.062 in. 1.6 mm 132955 V−Knurled

0.068−0.072 in. 0.068−0.072 in. 1.8 mm 132959 V−Knurled

0.079 in. 0.079 in. 2.0 mm 132960 V−Knurled

0.045 in. 0.045 in. 1.2 mm 083489 U−Cogged

0.052 in. 0.052 in. 1.3 mm 083490 U−Cogged
1/16 in. 0.062 in. 1.6 mm 053708 U−Cogged
5/64 in. 0.079 in. 2.0 mm 053710 U−Cogged

S-0859

OM-267043 Page 36

Warranty Questions?

Call
1-800-4-A-MILLER
for your local
Miller distributor.

Your distributor also gives
you ...

Service

You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.

Support

Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.

Effective January 1, 2016

(Equipment with a serial number preface of MG or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

LIMITED WARRANTY − Subject to the terms and conditions below,
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
retail purchaser that new Miller equipment sold after the effective
date of this limited warranty is free of defects in material and
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or replace
any warranted parts or components that fail due to such defects in
material or workmanship. Miller must be notified in writing within
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
followed. If notification is submitted as an online warranty claim, the
claim must include a detailed description of the fault and the
troubleshooting steps taken to identify failed components and the
cause of their failure.

Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time periods.
All warranty time periods start on the delivery date of the equipment
to the original end-user purchaser, and not to exceed twelve months
after the equipment is shipped to a North American distributor or
eighteen months after the equipment is shipped to an International
distributor.

1. 5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,

Diodes, and Discrete Rectifier Modules

2. 3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic

Series) (No Labor)

* Engine Driven Welder/Generators

(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)

* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Transformer/Rectifier Power Sources

3. 2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only

(No Labor)

* Fume Extractors − Capture 5, Filtair 400 and Industrial

Collector Series

4. 1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* Desiccant Air Dryer System
* External Monitoring Equipment and Sensors
* Field Options

(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in,
or for a minimum of one year — whichever is
greater.)

* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers

(NOTE: Digital Recorders are Warranted Separately
by the Manufacturer.)

* LiveArc Welding Performance Management System
* Load Banks
* Motor-Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems
* TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)

guarantees or warranties expressed or implied.

5. 6 Months — Parts
* Batteries
* Bernard Guns (No Labor)
* Tregaskiss Guns (No Labor)

6. 90 Days — Parts
* Accessory (Kits)
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls
* M-Guns
* MIG Guns and Subarc (SAW) Torches
* Remote Controls and RFCS-RJ45
* Replacement Parts (No labor)
* Roughneck Guns
* Spoolmate Spoolguns

Miller’s True Blue® Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)

2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon actual
use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.

Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.

In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and to
the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary from province to province.

miller_warr 2016-01

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
Welding Process Handbooks

To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]

For International Locations Visit

www.MillerWelds.com

Contact the Delivering Carrier to:

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2016 Miller Electric Mfg. Co. 2016−01

File a claim for loss or damage during
shipment.

For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.